DeZURIK
2-24” (50-600mm)
KGC ES or HD
KNIFE GATE VALVES
Instruction D10411
July 2013
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Instructions
These instructions are intended for personnel who are responsible for the installation, operation and
maintenance of your KGC knife gate valve, including models KGC-ES, KGC-HD, KGC-GV, KGC-MV
and KGC-SV in sizes 2-24”.
Safety Messages
All safety messages in the instructions are flagged with the word Caution, Warning or Danger. These
messages must be followed exactly to avoid equipment damage, personal injury or death.
Safety label(s) on the product indicate hazards that can cause equipment damage, personal injury or
death. If a safety label becomes difficult to see, or if a label has been removed, please contact
DeZURIK for replacement.
WARNING
Personnel involved in the installation or maintenance of valves should be constantly alert to potential emission of process material and take appropriate safety
precautions. Always wear suitable protection when dealing with hazardous process materials. Handle valves which have been removed from service with the
assumption of process material within the valve.
Inspection
Your KGC knife gate valve has been packaged to provide protection during shipment. Carefully inspect the unit for damage upon arrival and file a claim with the carrier if damage is apparent.
Parts
Recommended spare parts are listed on the assembly drawing. These parts should be stocked to
minimize downtime.
Order parts from your DeZURIK sales representative, or directly from DeZURIK. When ordering parts,
please include the 7-digit part number and 4-digit revision number (example: 9999999R000) located
on the data plate attached to the valve assembly. Also include the part name, the assembly drawing
number, the balloon number and the quantity stated on the assembly drawing.
DeZURIK Service
DeZURIK Service personnel are available to install, maintain and repair all DeZURIK products.
DeZURIK also offers customized training programs and consultation services. For more information,
contact your local DeZURIK representative or visit our website at www.dezurik.com.
D10411
© 2013 DeZURIK
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Table of Contents
Description
4
Installation
4
Operation
5
Lubrication
5
Packing
5
Adjustment
5
Drawings
6
Packing Replacement
7
Removing the Old Packing
7
Installing the New Packing
8
Reassembling the Valve
9
Seat Replacement
9
10
Reassembling the Valve
Troubleshooting
July 2013
13
Page 3
D10411
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Description
KGC knife gate valves have a stainless steel body and gate, and an all-metal or resilient-faced seat.
The KGC knife gate valve is available in 2-48" (50-1200mm) sizes. This manual covers the 2-24” (50600mm) sizes. A choice of several actuators and accessories is available.
Installation
Install the valve between ANSI Class 125 or Class 150 pipeline flanges, or other flanges that match
valve end connection. Flange gaskets are required. Before installation, remove foreign material such
as weld spatter, oil, grease, and dirt from the valve and pipeline.
Normal Installations
Install the valve so that the side marked “SEAT” is on the lower
pressure side of the valve when the valve is closed; the pipeline
pressure will then help seal the valve in the closed position.
Gravity (Dry) Service Installations
When installing the valve in a vertical pipeline (such as a hopper
bottom, gravity flow, or other dry service application), install the
SEAT side of the valve facing upstream as shown in Figure 1.
Installing the valves with the seat side upstream prevents process
media buildup in the seat and chest area of the valve. This orientation also allows the seat to act as an integral deflection cone,
protecting the seat from wear.
General Guidelines
Observe the following points to prevent distortion of the valve
body and gate when the flange bolts are tightened:


Align the mating pipeline flanges.
Figure 1—Vertical Line/
Hopper Bottom
Table A: Recommended Flange Bolt/Stud
Select the length of the flange bolts so
Torque Range in ft-lbs (non-lubricated)
that the bolts used in the blind holes
near the chest area of the valve do not
ASME Gasket Types
bottom out when tightened. We recomRubber
with Soft Elastomer
mend using studs with nuts in the blind
Valve Size
Soft Fabric
Gasket Shore
holes.
Filler, & 1/8”
Durometer <
Thick
Hard
75A
 Tighten the flange bolts evenly, in a
2” (50mm)
26 - 29
8-9
crisscross pattern. Refer to Table A for
3” (80mm)
37 - 41
14 - 16
recommended flange bolt/stud torques.
4” (100mm)
26 - 29
11 - 12
Note: Torque ranges are based on ASME Pres- 6” (150mm)
41 - 45
22 - 24
sure Vessel Code Calculations and lab test
8” (200mm)
55 - 61
35 - 39
data. These torques are only for the listed gas10” (250mm)
56 - 62
40 - 44
ket types. For other gasket types listed in
12” (300mm)
80 - 88
59 - 65
ASME, consult DeZURIK.
14” (350mm)
107 - 118
81 - 89
16” (400mm)
103 - 114
79 - 87
After installing the valve, pressurize pipeline and
18”
(450mm)
128
141
102
- 112
ensure the packing is not leaking. If the packing
20” (500mm)
123 - 136
99 - 109
leaks, adjust the packing as described on the next
page.
24” (600mm)
188 - 207
155 - 171
D10411
Page 4
July 2013
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Operation
The gate in the valve is positioned by the valve actuator. The actuator moves the gate over the valve
port in the closed position, and withdraws the gate from the seat in the open position. Refer to the Actuator Instructions for adjustment and maintenance requirements for the actuator.
Lubrication
The valve does not require lubrication. Refer to the Actuator Instructions for lubrication requirements
for the actuator.
Packing
The gate packing is contained and compressed by the packing gland. See Figure 2 for component
identification.
Note: The packing gland is slightly loosened prior to shipping. This is done to increase the life of the
packing during extended storage.
Adjustment
If packing leaks, tighten the adjustment nuts on top of the packing gland. Tighten the nuts evenly and
gently just enough to stop the leak. Over tightening will cause excessive operating forces, and will decrease the life of the packing.
July 2013
Page 5
D10411
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Drawings
Bolt (A5)
Nut (A7)
Washer (A6)
Gate (A3)
Packing Gland (A4)
Packing (A2)
Packing Cord (A8) (if supplied)
Packing (A2)
Anti Extrusion Ring (A9)
(if supplied)
Body (A1)
Seat (A10)
Body (A1)
Removable Seat Detail
Figure 2—Component Identification
D10411
Page 6
July 2013
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Packing Replacement
Removing the Old Packing
WARNING!
Pipeline pressure can cause personal injury or equipment damage. Relieve pipeline pressure before removing gate stem and packing gland nuts.
1. Relieve the pressure in the pipeline and close the valve.
WARNING!
Accidental operation of power actuator can cause personal injury or equipment
damage. Disconnect and lock out power to actuator before servicing.
2. If the actuator is powered, disconnect and lock out power to prevent accidental operation of the actuator.
3. Remove the two screws and nuts near the top of the gate and disengage the stem from the gate by
stroking the actuator (not the valve) to the open position.
4. Remove the gland nuts (A7), bolts (A5) and packing gland (A4).
5. Remove the used packing (A2), anti-extrusion ring (A9) if supplied and packing cord (A8) if supplied, from the packing chamber.
July 2013
Page 7
D10411
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Installing the New Packing
Packing (A2) strip length and quantity are shown in Table B. Ensure the inside and outside edges of
each ring are packed against the gate and packing chamber, so that each strip is compressed flat
and evenly.
Do not compress the packing any more than
needed to stop leaks.
Table B: Packing Ring and Packing Cord
Length & Quantity
1. Ensure the gate (A3) is fully closed and centered in the body before packing.
Valve Size
2. If used, place the anti-extrusion ring (A9) or
scraper ring in the bottom of the packing
chamber.
7.50
3” (80mm)
9.50
5” (125mm)
3. Assemble and pack the rings one at a time,
with the ends together, but not overlapped
Length,
Qty
Quantity
inches
Cord
2” (50mm)
4” (100mm)
Note: Ensure that the anti-extrusion ring fits
tightly around the gate and that there is approximately 1/32-1/16" clearance around the packing
chamber.
Square
Size
3/8”
11.50
13.50
6” (150mm)
15.50
8” (200mm)
20.00
10” (250mm)
25.00
12” (300mm)
14” (350mm)
Note: Stagger the joints, on the long side of the
packing chamber. For packing rings, we recom- 16” (400mm)
mend using a square-ended wood or plastic tool,
18” (450mm)
driven by a hammer or mallet. Do not use a
sharp tool to pack the rings.
20” (500mm)
1/2”
29.00
32.00
4 w/o
anti-ext
ring or
cord
1
3 w/o
cord
36.75
41.25
5/8”
45.25
2 with
cord
24” (600mm)
53.50
4. For packing systems with the packing cord
(A8), assemble and pack one row of packing (A2) and then insert the packing cord (A8). Assemble and pack the last row of packing. See detail below:
Packing
Cord
Standard
Scraper
Ring
Packing (A2)
Packing (A2)
Packing
Cord
(A8)
Scraper
Ring
(A9)
Anti-Extrusion
Ring
(A9) if supplied
Figure 3—Packing Ring Detail
D10411
Page 8
July 2013
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Reassembling Valve
1. Replace the packing gland (A4), bolts (A5), washer (A6) and nuts (A7). Tighten the nuts evenly
and finger tight, plus 1/2 turn.
2. Reconnect the stem to the gate with the two screws and nuts.
3. If the actuator is a powered actuator, reconnect power to the actuator.
4. Pressurize the pipeline and inspect packing for leakage.
5. If packing leaks, tighten the adjustment nuts on top of the packing gland. Tighten the nuts evenly
and gently - just enough to stop the leak. Over tightening will cause excessive operating forces,
and will decrease the life of the packing.
Replacing the Seat
See Figure 2 for component identification.
WARNING!
Pipeline pressure can cause personal injury or equipment damage. Relieve pipeline pressure before removing gate stem and packing gland nuts.
1. Relieve the pressure in the pipeline and close the valve.
WARNING!
Accidental operation of power actuator can cause personal injury or equipment
damage. Disconnect and lock out power to actuator before servicing.
2. If the actuator is powered, disconnect and lock out power to prevent accidental operation of the
actuator.
3. Remove the two screws and nuts near the top of the gate and disengage the stem from the gate.
4. Remove the pipeline flange bolts and flange from the side of the valve body opposite the word
“SEAT”. As an alternative, remove both flanges, and remove the valve from the pipeline.
5. Remove the actuator yoke and actuator from the valve.
Seat (A10)
6. Remove the gland nuts (A7), washers (A6), and packing
gland (A4).
7. Remove the gate (A3) from the body.
Body (A1)
8. Remove the packing (A2) from the packing chamber.
9. Remove the seat. Push the top of the removable seat (A10)
toward the center of the valve, and remove the seat through
the packing chamber.
Figure 4—Seat
10. Install the new replaceable seat:
a. Note the gate side and body side of the seat as shown in Figure 4.
b. Insert the new seat (A10) through the packing chamber.
c. Place the seat behind the lug at the 5 and 7 o‘clock positions in the body. Then push the
top of the seat into position.
July 2013
Page 9
D10411
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Seat Replacement Continued
Reassembling the Valve
1. Reassemble the gate (A3) in the body, with the beveled edge facing away from the resilient seat.
See Figure 4.
2. Place the gate in the fully closed position.
3. Reassemble the packing, as described in “Installing New Packing”.
4. Reassemble the packing gland (A4), washers (A6), nuts (A7) and bolts (A5). Tighten the nuts
evenly to finger tight, plus 1/2 turn.
5. Reassemble the yoke and actuator on the valve.
6. Reconnect the stem to the gate with the two screws and locknuts.
7. Reassemble the pipeline flange and flange bolts, or reassemble the valve in the pipeline if the
valve was removed. Refer to the requirements in the “Installation” section.
8. If the actuator is a powered actuator, reconnect power to the actuator.
9. Pressurize the pipeline and inspect the valve for leaks.
10. If the packing leaks, tighten the adjustment nuts (A7) on top of the packing gland. Tighten the nuts
evenly and slowly, just enough to stop the leakage. Over tightening will cause excessive operating
forces, and will decrease the life of the packing.
Replacing the Gate
See Figure 2 for component identification.
WARNING!
Pipeline pressure can cause personal injury or equipment damage. Relieve pipeline pressure before removing gate stem and packing gland nuts.
1. Relieve the pressure in the pipeline and close the valve.
WARNING!
Accidental operation of power actuator can cause personal injury or equipment
damage. Disconnect and lock out power to actuator before servicing.
2. If the actuator is powered, disconnect and lock out power to prevent accidental operation of the
actuator.
3. Remove the pipeline flange bolts, and remove the valve from the pipeline.
4. Remove the actuator, actuator yoke, packing gland (A4), and packing (A2) from the valve.
5. Remove and inspect the gate (A3). If the gate appears to be scratched or galled due to too-long
flange bolts in the chest area of the body, check for body damage in the tapped flange holes and
within the chest cavity. Carefully check the seat for damage. Repair or replace the body, as appropriate.
D10411
Page 10
July 2013
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Gate Replacement Continued
6. Remove and inspect the seat components.
7. Replace or reinstall the seat components as described in step 10 in the “Seat Replacement “ section.
8. Place the new gate (A3) in the body, in the fully closed position.
9. Replace or reinstall the packing (A2) as described in “Installing New Packing”.
10. Replace the yoke and actuator on the valve.
11. Adjust the actuator, yoke, and packing gland so that the valve actuates smoothly full stroke in both
directions, and so that there is no evidence of binding or scratching on the gate when the gate is
visible in the fully open position.
12. Reinstall the valve in the pipe line —see “Installation” section.
13. If the actuator is a powered actuator, reconnect power to the actuator.
14. Pressurize the pipeline and inspect the valve for leaks.
15. If the packing leaks, tighten the adjustment nuts (A7) on top of the packing gland.
Note: Tighten the nuts evenly and slowly, just enough to stop the leakage. Over tightening will cause
excessive operating forces, and will decrease the life of the packing.
Purge Port Option
When purge port options are ordered as illustrated, the intent is that the installer will connect purge
lines.
WARNING!
If pipeline is under pressure with purge port plugs in place, release line pressure
before removing plugs. Serious or fatal injury may occur if not complied with.
Installation:
1. Remove all purge plugs after valve has been installed in line and before line is pressurized.
2. Connect proper purge line to the ports.
3. Pressurize purge lines and check for leaks.
4. Pressurize pipe line.
See Figure 5 for Purge Port sizes and locations.
July 2013
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D10411
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Purge Port Options
VALVE SIZE
INCH
MM
2
50
3
80
4
100
5
125
6
150
8
200
10
250
12
300
14
350
16
400
18
450
20
500
24
600
A
1/4 ”
3/8 ”
1/2 ”
3/4 ”
Figure 5—Purge Port Sizes and Locations
D10411
Page 12
July 2013
DeZURIK
2-24” KGC ES or HD KNIFE GATE VALVES
Troubleshooting
Possible Causes
Corrective
Action
Packing is loose
Adjust packing gland
Packing is worn or torn
Replace packing
Packing leaks and gate is galled
Packing is worn or torn
Replace packing and
gate, check seat for
damage
Valve leaks when fully closed,
with no evidence of galling on
gate
Seat is worn or torn
Replace seat
Valve leaks when fully closed and
gate is galled
Seat is worn or torn
Replace gate and seat
Condition
Packing leaks, with no evidence
of galling on gate
July 2013
Page 13
D10411
Guarantee
Products, auxiliaries and parts thereof of DeZURIK, Inc. manufacture are warranted to the original purchaser for a period of twenty-four (24)
months from date of shipment from factory, against defective workmanship and material, but only if properly installed, operated and serviced in accordance with DeZURIK, Inc. recommendations. Repair or replacement, at our option, for items of DeZURIK, Inc. manufacture
will be made free of charge, (FOB) our facility with removal, transportation and installation at your cost, if proved to be defective within such
time, and this is your sole remedy with respect to such products. Equipment or parts manufactured by others but furnished by DeZURIK,
Inc. will be repaired or replaced, but only to the extent provided in and honored by the original manufacturers warranty to DeZURIK, Inc., in
each case subject to the limitations contained therein. No claim for transportation, labor or special or consequential damages or any other
loss, cost or damage shall be allowed. You shall be solely responsible for determining suitability for use and in no event shall DeZURIK,
Inc. be liable in this respect. DeZURIK, Inc. does not guarantee resistance to corrosion, erosion, abrasion or other sources of failure, nor
does DeZURIK, Inc. guarantee a minimum length of service. Your failure to give written notice to us of any alleged defect under this warranty within twenty (20) days of its discovery, or attempts by someone other than DeZURIK, Inc. or its authorized representatives to remedy
the alleged defects therein, or failure to return product or parts for repair or replacement as herein provided, or failure to install and operate
said products and parts according to instructions furnished by DeZURIK, Inc., or misuse, modification, abuse or alteration of such product,
accident, fire, flood or other Act of God, or failure to pay entire contract price when due shall be a waiver by you of all rights under this warranty.
The foregoing guarantee shall be null and void if, after shipment from our factory, the item is modified in any way or a component of another
manufacturer, such as but not limited to, an actuator is attached to the item by anyone other than DeZURIK, Inc. Factory Service personnel.
All orders accepted shall be deemed accepted subject to this limited warranty, which shall be exclusive of any other or previous Warranty,
and this shall be the only effective guarantee or warranty binding on DeZURIK, Inc., despite anything to the contrary contained in the purchase order or represented by any agent or employee of DeZURIK, Inc., in writing or otherwise, notwithstanding, including but not limited to
implied warranties.
THE FOREGOING REPAIR AND REPLACEMENT OBLIGATIONS ARE IN LIEU OF ALL OTHER WARRANTIES, OBLIGATIONS AND
LIABILITIES, INCLUDING ALL WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR OF MERCHANTABILITY OR OTHERWISE, EXPRESSED OR IMPLIED IN FACT OR BY LAW, AND STATE DEZURIK, INC.’S ENTIRE AND EXCLUSIVE LIABILITY AND
YOUR EXCLUSIVE REMEDY FOR ANY CLAIM IN CONNECTION WITH THE SALE AND FURNISHING OF SERVICES, GOODS OR
PARTS, THEIR DESIGN, SUITABILITY FOR USE, INSTALLATION OR OPERATIONS.
Limitation of liability
LIMITATION OF LIABILITY: IN NO EVENT SHALL DEZURIK, INC. BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES WHATSOEVER, AND DEZURIK, INC.’S LIABILITY, UNDER NO CIRCUMSTANCES, WILL EXCEED THE CONTRACT PRICE FOR THE GOODS AND/OR SERVICES FOR WHICH LIABILITY IS CLAIMED. ANY ACTION BY YOU FOR BREACH OF
CONTRACT MUST BE COMMENCED WITHIN 12 MONTHS AFTER THE DATE OF SALE.
Sales and Service
For information about our worldwide locations, approvals, certifications and local representative:
Web site: www.dezurik.com
E-Mail: info@dezurik.com
250 Riverside Ave. N. Sartell, Minnesota 56377 ● Phone: 320-259-2000 ● Fax: 320-259-2227
DeZURIK, Inc. reserves the right to incorporate our latest design and material changes without notice or obligation.
Design features, materials of construction and dimensional data, as described in this manual, are provided for your information only
and should not be relied upon unless confirmed in writing by DeZURIK, Inc. Certified drawings are available upon request.